Method and apparatus for fabricating liquid crystal display device and substrate base material for liquid crystal display device

ABSTRACT

A plurality of liquid crystal cells are formed by encapsulating pieces of liquid crystal material with in a plurality of first sealing members, respectively, between a pair of flexible substrate base materials. Only respective parts of the pair of substrate base materials are contained inside a vacuum container, and the liquid crystal cells are formed inside the vacuum container reduced in pressure.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority under 35 U.S.C. §119 on PatentApplication No. 2004-220109 filed in Japan on Jul. 28, 2004, the entirecontents of which are hereby incorporated by reference.

BACKGROUND OF THE INVENTION

(1) Field of the Invention

The present invention relates to a method and apparatus for fabricatinga flexible liquid crystal display device and a substrate base materialfor the flexible liquid crystal display device.

(2) Description of Related Art

Liquid crystal display devices each have a liquid crystal layersandwiched between a pair of substrates. Typically, a pair of glasssubstrates are used as the pair of substrates. Methods for fabricating aliquid crystal display device include the following known methods: amethod in which liquid crystal material is dropped onto one of the pairof glass substrates and then the glass substrates is bonded to the otherglass substrate; and a method in which the pair of glass substrates arepreviously bonded to each other and then liquid crystal material isvacuum-injected into cells formed between the pair of glass substrates.Both the methods need be carried out inside a vacuum container.

By the way, it has been known that when, instead of the glasssubstrates, flexible plastic substrates are used for liquid crystaldisplay devices, images are displayed with the whole liquid crystaldisplay devices curved significantly. Applications of the liquid crystaldisplay devices include electronic paper and wearable displays, such aswatches.

When a plurality of liquid crystal display devices with a pair ofplastic substrates are fabricated, they are preferably fabricatedspatially continuously from a pair of rolled or long-sheet-like plasticsubstrate base materials in terms of the improvement of productionefficiency.

However, it is difficult to contain the whole plastic substrate basematerials inside the vacuum container, because the plastic substratebase materials inevitably become relatively large. Furthermore, theproduction cost increases, because the vacuum container itself must bemade larger.

To cope with this, it has conventionally been known that each basematerial is sectioned into liquid crystal cells by a double-sealstructure, all adjacent pairs of the liquid crystal cells are allowed tocommunicate with each other through a connection path, and liquidcrystal material is not injected into the liquid crystal cells inside avacuum container (see, for example, Japanese Unexamined PatentPublication No. 62-150283).

More particularly, seals are provided on the top surfaces of the plasticsubstrates to surround the liquid crystal cells, respectively, and thenthe plastic substrates are bonded to each other by a pressure roller. Alittle larger amount of the liquid crystal material than a necessaryamount thereof is dropped onto the liquid crystal cells at the positionat which the plastic substrates are bonded to each other. In this way,air bubbles in the liquid crystal material are expelled through theconnection path.

SUMMARY OF THE INVENTION

However, it is extremely difficult to completely remove air bubbles fromthe liquid crystal cells by the known method, because liquid crystaldisplay devices are not actually fabricated inside the vacuum container.

The present invention has been made in view of the above-describedproblem, and its object is to provide a flexible liquid crystal displaydevice that can be fabricated spatially continuously without using alarge vacuum container and certainly remove air bubbles from liquidcrystal cells.

In order to achieve the above-described object, the present invention isconfigured to contain only respective parts of a pair of substrate basematerials in a vacuum container and form liquid crystal cells inside thevacuum container.

To be specific, in a method for fabricating a liquid crystal displaydevice of the present invention in which a plurality of liquid crystalcells are formed by encapsulating pieces of liquid crystal materialwithin a plurality of first sealing members, respectively, between apair of flexible substrate base materials and then separated from oneanother, only respective parts of the pair of substrate base materialsare contained inside a vacuum container, and the liquid crystal cellsare formed inside the vacuum container reduced in pressure.

The method of the present invention preferably comprises: a firstsealing member formation step of setting, on one of the pair ofsubstrate base materials, a plurality of liquid crystal cell formationregions in which the liquid crystal cells are formed at predeterminedintervals and forming the plurality of first sealing members in eachsaid liquid crystal cell formation region, each said plurality of firstsealing member being of closed configuration; a liquid crystal supplyingstep of supplying the liquid crystal material into recesses defined bythe respective inner perimetrical surfaces of the first sealing membersand the adjacent surface of the one of the substrate base materials; acontainment step of containing at least one of the liquid crystal cellformation regions inside the vacuum container; and a bonding step ofbonding the pair of substrate base materials to each other by reducingthe vacuum container in pressure.

The method of the present invention may comprise: a first sealing memberformation step of setting, on one of the pair of substrate basematerials, a plurality of liquid crystal cell formation regions in whichthe liquid crystal cells are formed at predetermined intervals andforming the plurality of first sealing members in each said liquidcrystal cell formation region; a bonding step of bonding the pair ofsubstrate base materials to each other; and a filling step of filling,with liquid crystal material, a plurality of cells located in the vacuumcontainer and defined by the plurality of first sealing members and thepair of substrate base materials.

It is preferable that the method of the present invention furthercomprises: a second sealing member formation step of forming, outsideeach said liquid crystal cell formation region, a second sealing memberinterposed between the pair of substrate base materials, wherein in thecontainment step, the vacuum container is sealed with the second sealingmember.

In the bonding step, one of the pair of substrate base materials may becut between the second sealing member and each said liquid crystal cellformation region, and then the vacuum container may be reduced inpressure.

The second sealing member may be formed into a line to separate adjacenttwo of the liquid crystal cell formation regions from each other.

The second sealing member may be formed into a closed configuration tosurround each said liquid crystal cell formation region.

The second sealing member may be composed of an elastic material.

The vacuum container may be composed of a stage on which the pair ofsubstrate base materials are placed and a vacuum chamber that covers thestage.

The cells may each have a fill opening through which the cells arefilled with liquid crystal material, and each said fill opening may beenclosed from one side with a third sealing member.

It is preferable that in the bonding step, the vacuum container isreduced in pressure and thereby the pair of substrate base materials areheld by the pair of holder plates while being sandwiched therebetweenand, in the filling step, the cells are filled with liquid crystalmaterial through communication holes allowing the cells to communicatewith the vacuum container, said communication holes being formed in oneof the holder plates.

An apparatus for fabricating a liquid crystal display device of thepresent invention in which a plurality of liquid crystal cells areformed by encapsulating pieces of liquid crystal material within aplurality of first sealing members, respectively, between a pair offlexible substrate base materials and then separated from one another,comprises: a vacuum container for containing only respective parts ofthe pair of substrate base materials; and a pressure reducer forreducing the vacuum container in pressure, said liquid crystal cellsbeing formed inside the vacuum container reduced in pressure by thepressure reducer.

It is preferable that the apparatus of the present invention furthercomprises: a first sealing member formation unit for setting, on one ofthe pair of substrate base materials, a plurality of liquid crystal cellformation regions in which the liquid crystal cells are formed atpredetermined intervals and forming the plurality of first sealingmembers in each said liquid crystal cell formation region, each saidplurality of first sealing member being of closed configuration; aliquid crystal supply unit for supplying the liquid crystal materialinto recesses defined by the respective inner perimetrical surfaces ofthe first sealing members and the adjacent surface of the one of thesubstrate base materials; and a bonding unit for bonding the pair ofsubstrate base materials to each other by reducing the vacuum containerin pressure, wherein the vacuum container is configured to contain atleast one of the liquid crystal cell formation regions.

The apparatus of the present invention may further comprise: a firstsealing member formation unit for setting, on one of the pair ofsubstrate base materials, a plurality of liquid crystal cell formationregions in which the liquid crystal cells are formed at predeterminedintervals and forming the plurality of first sealing members in eachsaid liquid crystal cell formation region; a bonding unit for bondingthe pair of substrate base materials to each other by reducing thevacuum container in pressure; and a filler for filling, with liquidcrystal material, a plurality of cells defined by the pair of substratebase materials and the plurality of first sealing members, said pair ofsubstrate base materials being bonded to each other inside the vacuumcontainer, wherein the vacuum container may be configured to contain atleast one of the liquid crystal cell formation regions.

The vacuum container may be composed of a stage on which the pair ofsubstrate base materials are placed and a vacuum chamber that covers thestage.

It is preferable that the cells each have a fill opening through whichthe cells are filled with liquid crystal material and each said fillopening may be enclosed from one side with a third sealing member.

The apparatus of the present invention may further comprise a pair ofholder plates for holding the pair of substrate base materials byreducing the vacuum container in pressure, wherein communication holesmay be formed in one of the holder plates to allow the cells tocommunicate with the vacuum container, and the cells may be filled withliquid crystal material through the communication holes.

A substrate base material for a liquid crystal display device of thepresent invention has a plurality of liquid crystal cell formationregions in each of which a plurality of liquid crystal cells are formed,said plurality of liquid crystal cell formation regions being arrangedat predetermined intervals.

—Effects—

Next, effects of the present invention will be described.

When a liquid crystal display device is fabricated, only respectiveparts of a pair of flexible substrate base materials are containedinside a vacuum container. Subsequently, liquid crystal material isencapsulated by first sealing members between the respective parts ofthe pair of substrate base materials contained in the vacuum containerreduced in pressure to form liquid crystal cells. Thereafter, the liquidcrystal cells are separated from one another, thereby fabricating aliquid crystal display device.

Fabrication methods for a liquid crystal display device according to thepresent invention include: a method of a first aspect in which liquidcrystal material is supplied between the pair of substrate basematerials before the pair of substrate base materials are bonded to eachother; and a method of a second aspect in which space between the pairof substrate base materials is filled with liquid crystal material afterthe pair of substrate base materials are bonded to each other.

The method of the first aspect comprises a first sealing memberformation step, a liquid crystal supplying step, a containment step, anda bonding step. In the first sealing member formation step, a pluralityof liquid crystal cell formation regions are set at predeterminedintervals on one of the pair of substrate base materials, and aplurality of first sealing members of closed configuration are formed ineach liquid crystal cell formation region. Thereafter, in the liquidcrystal supplying step, liquid crystal material is supplied intorecesses defined by the respective inner perimetrical surfaces of thefirst sealing members and the adjacent surface of the one of the pair ofsubstrate base materials. Subsequently, in the containment step, atleast one of the liquid crystal cell formation regions is containedinside a vacuum container. In this way, only respective parts of thepair of substrate base materials are contained in the vacuum container.Thereafter, in the bonding step, air bubbles are removed from therecesses by reducing the vacuum container in pressure, thereby bondingthe pair of substrate base materials to each other.

The method of the second aspect comprises a first sealing memberformation step, a containment step, a bonding step, and a filling step.In the first sealing member formation step, a plurality of liquidcrystal cell formation regions are set on one of the pair of substratebase materials at predetermined intervals, and a plurality of sealingmembers are formed in each liquid crystal cell formation region.Thereafter, in the containment step, at least one of the liquid crystalcell formation regions is contained inside a vacuum container. In thisway, only respective parts of the pair of substrate base materials arecontained inside the vacuum container. Thereafter, in the bonding step,the pair of substrate base materials are bonded to each other byreducing the vacuum container in pressure. Subsequently, in the fillingstep, a plurality of cells defined by the plurality of first sealingmembers in the vacuum container and the respective parts of the pair ofsubstrate base materials are filled with liquid crystal material. Inthis way, a vacuum can be produced by reducing the cells in pressure.Therefore, air bubbles can be removed from the liquid crystal cells.

Furthermore, a second sealing member is formed outside each liquidcrystal cell formation region. Therefore, the vacuum container can besealed with the second sealing member.

Moreover, the cells each have a fill opening through which the cells arefilled with liquid crystal material, and the fill opening is enclosedfrom one side with a third sealing member. This can prevent excess partof the liquid crystal material from leaking out when the cells arefilled with the liquid crystal material.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view showing the lower one of a pair of substrate basematerials of a first embodiment.

FIG. 2 is a cross-sectional view of a liquid crystal display device,which explains a first sealing member formation step, a second sealingmember formation step, and a liquid crystal supplying step.

FIG. 3 is a cross-sectional view of part of a fabrication apparatus fora liquid crystal display device, which explains an alignment step.

FIG. 4 is a cross-sectional view of part of the fabrication apparatusfor a liquid crystal display device, which explains a curing step.

FIG. 5 is a cross-sectional view of the fabrication apparatus for aliquid crystal display device, which explains a containment step.

FIG. 6 is a cross-sectional view of the fabrication apparatus for aliquid crystal display device, which explains a bonding step.

FIG. 7 is a cross-sectional view of a fabrication apparatus for a liquidcrystal display device of a second embodiment, which explains a bondingstep.

FIG. 8 is a cross-sectional view of a fabrication apparatus for a liquidcrystal display device of a third embodiment, which explains analignment step.

FIG. 9 is a cross-sectional view of the fabrication apparatus for aliquid crystal display device of the third embodiment, which explains abonding step.

FIG. 10 is a cross sectional view of a fabrication apparatus for aliquid crystal display device of a fourth embodiment, which explains acontainment step.

FIG. 11 is a cross-sectional view of the fabrication apparatus for aliquid crystal display device of the fourth embodiment, which explainsan alignment step.

FIG. 12 is a cross-sectional view of the fabrication apparatus for aliquid crystal display device of the fourth embodiment, which explains abonding step.

FIG. 13 is a plan view showing the lower one of a pair of substrate basematerials of a fifth embodiment.

FIG. 14 is a plan view showing a cell having a fill opening.

FIG. 15 is a cross-sectional view of a fabrication apparatus for aliquid crystal display device of the fifth embodiment, which explains aprocess from a containment step to a bonding step.

FIG. 16 is a cross-sectional view of the fabrication apparatus for aliquid crystal display device of the fifth embodiment, which explains afilling step.

FIG. 17 is a cross-sectional view of a liquid crystal display device ofthe fifth embodiment, which explains the filling step.

FIG. 18 is a cross-sectional view of the liquid crystal display deviceof the fifth embodiment, which explains the filling step.

FIG. 19 is a cross-sectional view of the liquid crystal display deviceof the fifth embodiment, which explains the filling step.

FIG. 20 is a cross-sectional view of a fabrication apparatus for aliquid crystal display device of a sixth embodiment, which explains abonding step.

FIG. 21 is a cross-sectional view of a fabrication apparatus for aliquid crystal display device of a seventh embodiment, which explains abonding step.

DETAILED DESCRIPTION OF THE INVENTION

Embodiments of the present invention will be described hereinafter indetail with reference to the drawings. The present invention is notlimited to the following embodiments.

Embodiment 1

FIGS. 1 through 6 show embodiments of a method and apparatus forfabricating a liquid crystal display device and a substrate basematerial for the liquid crystal display device according to the presentinvention.

FIG. 1 is a plan view showing the lower one of a pair of substrate basematerials 11 of the liquid crystal display device. A liquid crystaldisplay device comprises liquid crystal cells 12 composed of a thin-filmtransistor (hereinafter, referred to as TFT) substrate formed with aplurality of switching elements, such as TFTs, an opposed substrateformed with a color filter or other elements, and a liquid crystal layerinterposed between the TFT substrate and the opposed substrate. Thestructure of each substrate is not restrictive. The TFT substrate may beformed with a color filter.

The liquid crystal display device is fabricated from a pair of substratebase materials 11. More particularly, one of the pair of substrate basematerials 11 is an aggregation of TFT substrates, and the other of thepair of substrate base materials 11 is an aggregation of opposedsubstrates. In this embodiment, each substrate base material 11 iscomposed of a flexible film, such as plastic.

A plurality of liquid crystal cells 12 are formed between the pair ofsubstrate base materials 11 by encapsulating liquid crystal material inregions surrounded by first sealing members 21 of closed configuration,and then separated from one another, thereby fabricating a liquidcrystal display device.

Alignment layers (not shown) are formed on the respective opposedsurfaces of the pair of substrate base materials 11, respectively, andhave been subjected to alignment using rubbing and then cleaned. Rubbingand cleaning are not required for some of liquid-crystal modes.

A plurality of liquid crystal cell formation regions S₁ in which liquidcrystal cells are formed are set on the lower one of the pair ofsubstrate base materials 11 at predetermined intervals. In other words,a strip-like marginal region So is formed between adjacent two of theliquid crystal cell formation regions S₁. In each liquid crystal cellformation region S₁, the liquid crystal cells 12 are arranged in amatrix array. The liquid crystal cell formation region S₁ is formed suchthat its size corresponds to the size of a vacuum container 15.

The first sealing members 21 are sandwiched between the pair ofsubstrate base materials 11 and formed to have a rectangular closedshape. Each liquid crystal cell formation region S₁ includes a pluralityof cells 10 defined by the respective inner perimetrical surfaces of thefirst sealing members 21 and the respective opposed surfaces of the pairof substrate base materials 11, and each cell 10 is filled with liquidcrystal material. In other words, each liquid crystal cell 12 iscomposed of the cell 10 and liquid crystal material with which theinside of the cell 10 is filled.

Meanwhile, second sealing members 22 are provided individually inregions between all adjacent pairs of the liquid crystal cell formationregions S₁ (i.e., the marginal regions S₀). Each of the second sealingmembers 22 is formed to extend linearly and orthogonally to thelongitudinal direction of the substrate base materials 11 and sandwichedbetween the pair of substrate base materials 11, thereby separating oneadjacent pair of the liquid crystal cell formation regions S₁ from eachother.

Each of the liquid crystal cell formation regions S₁ interposed betweenadjacent pairs of the second sealing members 22 is contained in thevacuum container 15 separately when the liquid crystal cells 12 areformed in the liquid crystal cell formation region S₁.

—Fabrication Method for Liquid Crystal Display Device—

Next, a fabrication method for a liquid crystal display device of thisembodiment will be described in detail. The fabrication method for aliquid crystal display device according to the present invention ischaracterized by containing not the whole of a pair of substrate basematerials 11 but only respective parts of the pair of substrate basematerials 11 inside a vacuum container 15 and forming liquid crystalcells 12 inside the vacuum container 15 reduced in pressure. Moreparticularly, the fabricating method for a liquid crystal display deviceof this embodiment comprises a first sealing member formation step, asecond sealing member formation step, a liquid crystal supplying step,an alignment step, a curing step, a containment step, and a bondingstep, and after the supply of liquid crystal material into the cells 10,the pair of substrate base materials 11 are bonded to each other.

The fabrication method is carried out using a fabrication apparatus fora liquid crystal display device. The fabrication apparatus comprises avacuum container 15, pressure reducers 51, such as vacuum pumps or thelike, a first sealing member formation unit 52, a second sealing memberformation unit 53, a liquid crystal supply unit 54, curing units 55, anda bonding unit 56, and is configured to form the liquid crystal cells 12inside the vacuum container 15 reduced in pressure by the pressurereducers 51.

First, in the first sealing member formation step, a plurality of liquidcrystal cell formation regions S₁ in each of which a plurality of liquidcrystal cells 12 are formed are set at predetermined intervals on thelower one of the pair of substrate base materials 11 (for example, a TFTsubstrate). In addition, as shown in FIG. 2, a plurality of firstsealing members 21 of closed configuration are formed in each liquidcrystal cell formation region S₁ by the first sealing member formationunit 52. First sealing members 21 are formed by applying a material ofthe first sealing member to the substrate base material 11 to surroundthe respective display areas of a liquid crystal display device. AUV/heat cure seal material for a one-drop-fill process, No. 780 (made byKyoritsu Chemical & Co., Ltd), is used for the first sealing member 21.A 5-μm-diameter glass spacer is mixed into the first sealing member 21.

The pair of substrate base materials 11 each have, for example, a widthof 400 mm and a length of 1600 mm. The pair of substrate base materials11 may be formed in a roll outside the vacuum container 15.

Next, in the second sealing member formation step, as shown in FIG. 2,second sealing members 22 are formed outside the liquid crystal cellformation region S₁ (i.e., in marginal regions S₀) by the second sealingmember formation unit 53. The second sealing members 22 are sandwichedbetween the pair of substrate base materials 11 in a later process step.The seal material, i.e., No. 780 (made by Kyoritsu Chemical & Co., Ltd),is used, like the first sealing members 21, for the second sealingmembers 22. 50-μm-diameter glass spacers 19 are mixed into the secondsealing members 22. The first and second sealing member formation units52 and 53 are configured to apply the material of the first and secondsealing members 21 and 22 in predetermined patterns to the top surfaceof the lower one of the pair of substrate base materials 11.

Subsequently, in the liquid crystal supplying step, as shown in FIG. 2,liquid crystal material 26 is supplied in drops, by the liquid crystalsupply unit 54, into recesses 25 defined by the respective innerperimetrical surfaces of the first sealing members 21 and the topsurface of the lower substrate base material 11. It is preferablysupplied into the recesses 25 in every one of the liquid crystal cellformation regions S1 that can be accommodated by the vacuum container 15at once. The liquid crystal supply unit 54 is configured to discharge apredetermined amount of the liquid crystal material 26.

Next, in the alignment step, as shown in FIG. 3, the lower substratebase material 11 on which the first sealing members 21 or other elementsare formed are put on a lower chamber 31 and held thereon using a vacuumforce. Furthermore, the upper substrate base material 11 is aligned withand overlaid on the lower substrate base material 11. In this case, thedistance between the pair of substrate base materials 11 is reduced suchthat the second sealing members 22 make contact with both the pair ofsubstrate base materials 11. In addition, holder plates 17 are placedimmediately above the top surface of the upper substrate base material11 and immediately below the bottom surface of the lower substrate basematerial 11, respectively.

Thereafter, in the curing step, as shown by arrows in FIG. 4, the pairof substrate base materials 11 are brought into contact with each otherby applying a pressure to the second sealing members 22. In addition,the second sealing members 22 are cured using the curing units 55 byapplying ultraviolet light to the second sealing members 22, forexample, at a dose of 2 J/cm². The curing units 55 are light sources forapplying light, such as ultraviolet light, to an object.

In this embodiment, in order to prevent the first sealing members 21from making contact with the upper substrate base material 11, the glassspacers 19 mixed into the second sealing members 22 each have a largerdiameter than the glass spacers mixed into the first sealing members 21.However, the respective glass spacers of the first and second sealingmembers 21 and 22 may be set to each have the same diameter. Moreparticularly, the pair of substrate base materials 11 may be bonded toeach other by bringing the first and second sealing members 21 and 22 incontact with the upper substrate base material 11 at the same time.

The second sealing members 22 may be composed of a material that will becured by applying electron beams thereto. Thus, instead of ultravioletlight, electron beams may be applied to the second sealing members 22.

Subsequently, the upper substrate base material 11 is cut between themarginal regions So and the liquid crystal cell formation region Si. Asshown in FIG. 4, a wedge-like cutter 27 is used to cut the uppersubstrate base material 11.

More particularly, when the pair of substrate base materials 11 arebonded to each other, at least the upper substrate base material 11(which is not fixed) need be depressed by physical deformation, becausethe distance between respective parts of the pair of substrate basematerials 11 located outside the liquid crystal cell formation region S₁is relatively large. Therefore, the cut of the upper substrate basematerial 11 in this embodiment can prevent stress concentration due tothe deformation of the upper substrate base material 11 in the vicinityof the second sealing members 22. As a result, the thicknesses of theliquid crystal cells in the fabricated liquid crystal display device canbe maintained with high accuracy.

When the respective glass spacers of the first and second sealingmembers 21 and 22 have the same diameter or when the pair of substratebase materials 11 or the second sealing members 22 are made of amaterial likely to become deformed, the upper substrate base material 11need not be cut.

Next, in the containment step, as shown in FIG. 5, an upper chamber 32is overlaid on the lower chamber 31 with the second sealing members 22and the pair of substrate base materials 11 interposed therebetween. Thelower chamber 31 and the upper chamber 32 constitute a vacuum container15. In this way, the liquid crystal cell formation region S₁ iscontained inside the vacuum container 15, and the inside of the vacuumcontainer 15 is sealed with the second sealing members 22.

Subsequently, in the bonding step, as shown in FIG. 6, the vacuumcontainer 15 is reduced in pressure by the pressure reducers 51, such asvacuum pumps, so that air is exhausted from the space between the pairof substrate base materials 11 to produce a vacuum. In this way, thepair of substrate base materials 11 are bonded to each other. Thebonding unit 56 for the pair of substrate base materials 11 is composedof the pressure reducers 51 and the holder plates 17. In this case, thepair of substrate base materials 11 are held by being sandwiched betweenthe holder plates 17 serving as a pair.

In this embodiment, as shown in FIG. 1, openings are formed betweenrespective parts of the pair of substrate base materials 11corresponding to the liquid crystal cell formation region S₁ to extendalong the longer edges of the liquid crystal cell formation region S₁.Therefore, the exhaust of air from these openings can produce a vacuumbetween the pair of substrate base materials 11.

If the inside of the vacuum container 15 has an atmospheric pressure of1 Torr or less and the distance between the pair of substrate basematerials 11 is made smaller, the pair of substrate base materials 11can be bonded to each other with higher accuracy. More particularly, thevacuum container 15 is further reduced in pressure so that the distancebetween the pair of substrate base materials 11 is reduced to apredetermined value. In this state, a previously formed part of eachfirst sealing member 21 through which the pair of substrate basematerials 11 are temporarily bonded to each other is cured.Alternatively, the first sealing member 21 is entirely radiated withultraviolet light so as to be cured to some extent. Thereafter, in orderto further promote the curing of the first sealing member 21, the firstsealing member 21 may be heated at 120° C. for 60 minutes. Since thepair of substrate base materials 11 are held by the holder plates 17,this can prevent the first sealing members 21 from partly coming offowing to the reduced pressure in the vacuum container 15 and also theupper substrate base material 11 from becoming deformed.

Thereafter, another liquid crystal cell formation region S₁ next to theliquid crystal cell formation region S₁ in which the liquid crystalcells 12 have been formed in the above-mentioned manner is fed into andcontained inside the vacuum container 15, and liquid crystal cells 12are formed in the same manner as described above. This is repeatedlycarried out.

As a result, pressure reduction in the vacuum container 15 makes thedistance between the pair of substrate base materials 11 smaller so thatthe pair of substrate base materials 10 are bonded to each other. Then,the inside of the cells 10 are filled with the liquid crystal material26, and air bubbles are removed from the cells 10. Thereafter, liquidcrystal display devices each having the liquid crystal cells 10 areseparated from one another.

Effects of Embodiment 1

In view of the above, according to this embodiment, only respectiveparts of the pair of flexible substrate base materials 11 are containedin the vacuum container 15, and the liquid crystal cells 12 are formedinside the vacuum container 15. Therefore, even if the pair of substratebase materials 11 are entirely very large, air bubbles are removed fromthe liquid crystal cells 12 without using a large vacuum container,thereby fabricating liquid crystal display devices. In addition,respective parts of the pair of substrate base materials 11 are fed intoand contained one pair of parts after another in the vacuum container15, which enables spatially continuous fabrication of liquid crystaldisplay devices. This can improve the product accuracy of the liquidcrystal display devices while reducing the production cost.

Embodiment 2

FIG. 7 is a cross-sectional view showing a second embodiment of afabrication apparatus for a liquid crystal display device of the presentinvention. In the following embodiments, the same components as those inFIGS. 1 through 6 are denoted by the same reference numerals, and thedescription thereof is omitted here.

In the first embodiment, the vacuum container 15 is composed of thelower chamber 31 and the upper chamber 32. On the other hand, in thisembodiment, a vacuum container 15 is composed of a stage 33 on which apair of substrate base materials 11 are placed and a vacuum chamber 34that covers the stage 33.

More particularly, in order to fabricate a liquid crystal displaydevice, in an alignment step of this embodiment, unlike the firstembodiment, the lower one of the pair of substrate base materials 11formed with the first sealing members 21 is placed on the stage 33 andheld by, for example, an electrostatic force. Thereafter, a bonding stepis carried out as shown in FIG. 7. The other steps are the same as thoseof the first embodiment.

In view of the above, the vacuum container 15 can be made smaller.Therefore, an apparatus for fabricating a liquid crystal display devicecan be wholly reduced in size.

Embodiment 3

FIGS. 8 and 9 are cross-sectional views showing a third embodiment of afabrication apparatus for a liquid crystal display device of the presentinvention.

In this embodiment, unlike the first embodiment, the second sealingmembers 22 are made of not an ultraviolet cure material but an elasticmaterial. The second sealing members 22 are preferably made of, forexample, rubber. Therefore, the second sealing members 22 are not bondedto the pair of substrate base materials 11.

In order to fabricate a liquid crystal display device, in the secondsealing member formation step, second sealing members 22 made of arubber material are formed in the marginal regions S₀. Since in thisembodiment no glass spacer is mixed into the second sealing members 22,the second sealing members 22 are compressed and thus become elasticallydeformed by pressure reduction in the vacuum container 15 as shown inFIG. 9. In view of the above, since in this embodiment stresses arerestrained from concentrating on the upper one of the substrate basematerials 22, the step of cutting the upper substrate base material 11can be omitted unlike the first embodiment. Therefore, a liquid crystaldisplay device can be fabricated more easily.

Embodiment 4

FIGS. 10 through 12 are cross-sectional views showing a fourthembodiment of a fabrication apparatus for a liquid crystal displaydevice of the present invention. In this embodiment, a liquid crystaldisplay device is fabricated without using second sealing members 22.

More particularly, in this embodiment, the second sealing memberformation step is not carried out unlike the first embodiment. As shownin FIGS. 10 and 11, in the liquid crystal display device containmentstep, an upper chamber 32 is overlaid on a lower chamber 31 with onlythe pair of substrate base materials 11 interposed therebetween. In thisway, the liquid crystal cell formation region S₁ is contained inside thevacuum container 15. Thereafter, in the bonding step, as shown in FIG.12, the pair of substrate base materials 11 are bonded to each other bypressure reduction in the vacuum container 15.

In view of the above, according to this embodiment, a liquid crystaldisplay device can be more easily formed.

Embodiment 5

FIGS. 13 through 19 show a fifth embodiment of a liquid crystal displaydevice and a fabrication apparatus for the liquid crystal display deviceof the present invention. In the first embodiment, the liquid crystalmaterial 26 is previously supplied into the recesses 25 located on thelower substrate base material 11 before the bonding of the pair ofsubstrate base materials 11 to each other. On the other hand, in thisembodiment, after a pair of substrate base materials 11 are bonded toeach other, cells 10 are filled with liquid crystal material.

FIG. 13 is a plan view showing the lower one of the pair of substratebase materials 11 of the liquid crystal display device. A second sealingmember 22 is formed to have a rectangular closed shape and surround theassociated one of liquid crystal cell formations region S₁. In otherwords, the liquid crystal cell formation region S₁ is surrounded by amarginal region S₀.

—Fabrication Method for Liquid Crystal Display Device—

Next, a fabrication method for a liquid crystal display device of thisembodiment will be described in detail. The fabrication method for aliquid crystal display device of this embodiment comprises a firstsealing member formation step, a second sealing member formation step,an alignment step, a bonding step, a curing step, a containment step,and a liquid crystal filling step. A fabrication apparatus for a liquidcrystal display device of this embodiment has a filler 57 for filling aplurality of cells with a crystal liquid material instead of the liquidcrystal supply unit 54 of the first embodiment. The filler 57 iscomposed of, for example, a mechanism for discharging a predeterminedamount of liquid crystal material and a pressure reducer 51.

In the first sealing member formation step, like the first embodiment, aplurality of first sealing members 21 are formed in each of liquidcrystal cell formation regions S₁ of the lower one of a pair ofsubstrate base materials 11. In this embodiment, as shown in FIG. 14,cells 10 defined by the first sealing members 21 and the pair ofsubstrate base materials 11 have fill openings 37, respectively, throughwhich they are filled with liquid crystal material. The fill openings 37are enclosed from one side with third sealing members 23, respectively.

More particularly, the fill openings 37 are formed by removing parts ofthe first sealing members 21, and the third sealing members 23 areformed continuously with the first sealing members 21 to enclose thefill openings 37 from one side. The third sealing members 23 are formedto each have a U shape when seen from the above.

Next, the second sealing member formation step is carried out like thefirst embodiment. In this relation, glass spacers to be mixed into thesecond sealing member 22 each have the same diameter as those to bemixed into the first sealing member 21, i.e., a diameter of 5 μm. Thefirst and second sealing members 21 and 22 may be made of the samematerial or different materials. In this embodiment, a heat cure sealmaterial, No. 780P (made by Kyoritsu Chemical & Co., Ltd), is used forboth the first and second sealing members 21 and 22. Otherwise, a UVcure seal material or a UV/heat cure seal material can be used for thefirst and second sealing members 21 and 22.

Thereafter, the pair of substrate base materials 11 placed on a stage 33are aligned with each other, and one of them is overlaid on another withthe first and second sealing members 21 and 22 interposed therebetween.The first and second sealing members 21 and 22 are cured by heat. Whenthe first and second sealing members 21 and 22 are made of a UV cureseal material, they are cured by ultraviolet light. When they are madeof a UV/heat cure seal material, they are cured by ultraviolet light orheat. Then, the containment step is carried out. In other words, asshown in FIG. 15, a vacuum chamber 34 is placed on the stage 33 with thepair of substrate base materials 11 and the second sealing member 22interposed therebetween. In this way, one of liquid crystal cellformation regions S₁ of the lower substrate base material 11 iscontained inside a vacuum container 15.

In this relation, through holes 41 are formed in the upper substratebase material 11 (which is not fixed) and above the U-shaped thirdsealing members 23 to extend vertically. Furthermore, communicationholes 42 are formed in the holder plate 17 continuously with the throughholes 41. This allows the inside of the vacuum container 15 tocommunicate with the inside of the cells 10.

Subsequently, as shown in FIG. 15, the vacuum container 15 is reduced inpressure. In this way, air is exhausted from the cells 10, which havebeen formed by bonding the pair of substrate base materials to eachother using the first sealing members 21, through the through holes 41and the communication holes 42, thereby producing a vacuum in each cell10.

Next, in the filling step, first, as shown in FIG. 16, the holder plate17 is lifted while the vacuum container 15 is reduced in pressure, andliquid crystal material 26 is dropped into the through holes 41 of theupper substrate base material 11. Subsequently, as shown in FIG. 17, thevacuum container 15 is increased in pressure so as to be returned tonormal atmospheric pressure. This allows the liquid crystal material 26to penetrate the inside of the cells 10 through the through holes 41 andthe fill openings 37. Thereafter, as shown in FIG. 18, excess part ofthe liquid crystal material 26 that lies off the respective edges of thecells 10 is wiped off so as to be removed. In addition, unnecessaryparts of the upper substrate base material 11 located above the thirdsealing members 23 are removed. Next, as shown in FIG. 19, therespective fill openings 37 of the cells 10 are blocked by blockingmembers 46 with a pressure applied to the upper substrate base material11 by pressure plates 45. In the above-mentioned manner, the cells 10are filled with the liquid crystal material 26, thereby forming liquidcrystal cells 12.

Thereafter, like the first embodiment, the liquid crystal cells 12 areseparated from one another, thereby fabricating a plurality of liquidcrystal display devices.

In view of the above, also according to this embodiment, the pair ofsubstrate base materials 11 are partly contained inside the vacuumcontainer 15, and the cells 10 are filled with the liquid crystalmaterial 26 inside the vacuum container 15. Therefore, air bubbles canbe sufficiently removed from the liquid crystal cells 12.

Furthermore, the fill openings of the cells 10 are enclosed from oneside with the third sealing members 23, respectively. This can preventexcess part of the liquid crystal material 26 from leaking out when thecells 10 are filled with the liquid crystal material 26.

Although in this embodiment the stage 33 serves as a holder plate, thepair of substrate base materials 11 may be held by a pair of holderplates 17 while being sandwiched therebetween as described in the firstembodiment and other embodiments.

Embodiment 6

FIG. 20 is a cross-sectional view showing a sixth embodiment of afabrication apparatus for a liquid crystal display device of the presentinvention.

A liquid crystal display device of this embodiment is fabricated likethe fifth embodiment with the exception that the second sealing member22 is not formed.

More particularly, in this embodiment, unlike the fifth embodiment, thesecond sealing member formation step is not carried out. In thecontainment step, a pair of substrate base materials 11 are partlycontained inside a vacuum container 15, and then, as shown in FIG. 20,the vacuum container 15 is reduced in pressure. In this way, air isexhausted from the inside of the cells 10 previously formed by bondingthe pair of substrate base materials 11 to each other using firstsealing members 21 through the through holes 41 and the communicationholes 42, thereby producing a vacuum. In this case, the pair ofsubstrate base materials 11 come into direct contact with each other ina marginal region S₀.

In view of the above, since in this embodiment second sealing members 22are not formed, a liquid crystal display device can be fabricated withease.

Embodiment 7

FIG. 21 is a cross-sectional view showing a seventh embodiment of afabrication apparatus for a liquid crystal display device of the presentinvention.

In this embodiment, unlike the sixth embodiment, the upper one of a pairof substrate base materials 11 (which is not fixed) previously bonded toeach other using first sealing members 21 is partly removed in themarginal region S₀.

More particularly, the upper substrate base material 11 is partlyremoved, and then the containment step is carried out. In thecontainment step, a vacuum chamber 34 is overlaid on a stage 33 with thelower one of the pair of substrate base materials 11 interposedtherebetween. In the above-mentioned manner, one of liquid crystal cellformation regions S₁ of the lower substrate base material 11 iscontained inside the vacuum container 15.

In view of the above, also according to this embodiment, a liquidcrystal display device can be fabricated with ease. Furthermore, the endof a region of the upper substrate base material 11 located in thevacuum chamber 34 is not elastically deformed, because it is not pressedby the vacuum chamber 34. Therefore, the thickness of each of formedliquid crystal cells 12 (cell gap) can be controlled with high accuracy.

As described above, the fabrication method and apparatus for a flexibleliquid crystal display device and the substrate base material for thesame of the present invention are useful and suitable, in particular,when a liquid crystal display device can be fabricated spatiallycontinuously without using a large vacuum container and air bubbles areto be removed from the liquid crystal cells with reliability.

1. A method for fabricating a liquid crystal display device in which aplurality of liquid crystal cells are formed by encapsulating pieces ofliquid crystal material within a plurality of first sealing members,respectively, between a pair of flexible substrate base materials andthen separated from one another, wherein only respective parts of thepair of substrate base materials are contained inside a vacuumcontainer, and the liquid crystal cells are formed inside the vacuumcontainer reduced in pressure.
 2. The method of claim 1 comprising: afirst sealing member formation step of setting, on one of the pair ofsubstrate base materials, a plurality of liquid crystal cell formationregions in which the liquid crystal cells are formed at predeterminedintervals and forming the plurality of first sealing members in eachsaid liquid crystal cell formation region, each said plurality of firstsealing member being of closed configuration; a liquid crystal supplyingstep of supplying the liquid crystal material into recesses defined bythe respective inner perimetrical surfaces of the first sealing membersand the adjacent surface of the one of the substrate base materials; acontainment step of containing at least one of the liquid crystal cellformation regions inside the vacuum container; and a bonding step ofbonding the pair of substrate base materials to each other by reducingthe vacuum container in pressure.
 3. The method of claim 2 furthercomprising: a second sealing member formation step of forming, outsideeach said liquid crystal cell formation region, a second sealing membersandwiched between the pair of substrate base materials, wherein in thecontainment step, the vacuum container is sealed with the second sealingmember.
 4. The method of claim 3, wherein in the bonding step, one ofthe pair of substrate base materials is cut between the second sealingmember and each said liquid crystal cell formation region, and then thevacuum container is reduced in pressure.
 5. The method of claim 3,wherein the second sealing member is formed into a line to separateadjacent two of the liquid crystal cell formation regions from eachother.
 6. The method of claim 3, wherein the second sealing member isformed into a closed configuration to surround each said liquid crystalcell formation region.
 7. The method of claim 3, wherein the secondsealing member is composed of an elastic material.
 8. The method ofclaim 2, wherein the vacuum container is composed of a stage on whichthe pair of substrate base materials are placed and a vacuum chamberthat covers the stage.
 9. The method of claim 1 comprising: a firstsealing member formation step of setting, on one of the pair ofsubstrate base materials, a plurality of liquid crystal cell formationregions in which the liquid crystal cells are formed at predeterminedintervals and forming the plurality of first sealing members in eachsaid liquid crystal cell formation region; a bonding step of bonding thepair of substrate base materials to each other; and a filling step offilling, with liquid crystal material, a plurality of cells located inthe vacuum container and defined by the plurality of first sealingmembers and the pair of substrate base materials.
 10. The method ofclaim 9 comprising a second sealing member formation step of forming,outside each said liquid crystal cell formation region, a second sealingmember sandwiched between the pair of substrate base materials, whereinin the containment step, the vacuum container is sealed with the secondsealing member.
 11. The method of claim 10, wherein in the bonding step,one of the pair of substrate base materials is cut between the secondsealing member and each said liquid crystal cell formation region, andthen the vacuum container is reduced in pressure.
 12. The method ofclaim 10, wherein the second sealing member is formed into a line toseparate adjacent two of the liquid crystal cell formation regions fromeach other.
 13. The method of claim 1O, wherein the second sealingmember is formed into a closed configuration to surround each saidliquid crystal cell formation region.
 14. The method of claim 10,wherein the second sealing member is composed of an elastic material.15. The method of claim 9, wherein the vacuum container is composed of astage on which the pair of substrate base materials are placed and avacuum chamber that covers the stage.
 16. The method of claim 9, whereinthe cells each have a fill opening through which the cells are filledwith liquid crystal material, and each said fill opening is enclosedfrom one side with a third sealing member.
 17. The method of claim 10,wherein in the bonding step, the vacuum container is reduced inpressure, and thereby the pair of substrate base materials are held bythe pair of holder plates while being sandwiched therebetween, and inthe filling step, the cells are filled with liquid crystal materialthrough communication holes allowing the cells to communicate with thevacuum container, said communication holes being formed in one of theholder plates.
 18. An apparatus for fabricating a liquid crystal displaydevice in which a plurality of liquid crystal cells are formed byencapsulating pieces of liquid crystal material within a plurality offirst sealing members, respectively, between a pair of flexiblesubstrate base materials and then separated from one another, saidapparatus comprising: a vacuum container for containing only respectiveparts of the pair of substrate base materials; and a pressure reducerfor reducing the vacuum container in pressure, said liquid crystal cellsbeing formed inside the vacuum container reduced in pressure by thepressure reducer.
 19. The apparatus of claim 18 further comprising: afirst sealing member formation unit for setting, on one of the pair ofsubstrate base materials, a plurality of liquid crystal cell formationregions in which the liquid crystal cells are formed at predeterminedintervals and forming the plurality of first sealing members in eachsaid liquid crystal cell formation region, each said first sealingmember being of closed configuration; a liquid crystal supply unit forsupplying the liquid crystal material into recesses defined by therespective inner perimetrical surfaces of the first sealing members andthe adjacent surface of the one of the substrate base material; and abonding unit for bonding the pair of substrate base materials to eachother by reducing the vacuum container in pressure, wherein the vacuumcontainer is configured to contain at least one of the liquid crystalcell formation regions.
 20. The apparatus of claim 19, wherein thevacuum container is composed of a stage on which the pair of substratebase materials are placed and a vacuum chamber that covers the stage.21. The apparatus of claim 18 further comprising: a first sealing memberformation unit for setting, on one of the pair of substrate basematerials, a plurality of liquid crystal cell formation regions in whichthe liquid crystal cells are formed at predetermined intervals andforming the plurality of first sealing members in each said liquidcrystal cell formation region; a bonding unit for bonding the pair ofsubstrate base materials to each other by reducing the vacuum containerin pressure; and a filler for filling, with liquid crystal material, aplurality of cells defined by the pair of substrate base materials andthe plurality of first sealing members, said pair of substrate basematerials being bonded to each other inside the vacuum container,wherein the vacuum container is configured to contain at least one ofthe liquid crystal cell formation regions.
 22. The apparatus of claim21, wherein the vacuum container is composed of a stage on which thepair of substrate base materials are placed and a vacuum chamber thatcovers the stage.
 23. The apparatus of claim 21, wherein the cells eachhave a fill opening through which the cells are filled with liquidcrystal material, and each said fill opening is enclosed from one sidewith a third sealing member.
 24. The apparatus of claim 21 furthercomprising a pair of holder plates for holding the pair of substratebase materials by reducing the vacuum container in pressure, whereincommunication holes are formed in one of the holder plates to allow thecells to communicate with the vacuum container, and the cells are filledwith liquid crystal material through the communication holes.
 25. Asubstrate base material for a liquid crystal display device, having aplurality of liquid crystal cell formation regions in each of which aplurality of liquid crystal cells are formed, said plurality of liquidcrystal cell formation regions being arranged at predeterminedintervals.